Blind cutting center with detachable vacuum bag

ABSTRACT

A method and apparatus for sizing window coverings slidably extendable from a bay into an aisle of a retail outlet. The method includes the steps of locating the center of the window covering relative to a cutting station utilizing a half scale for removing a portion of the window covering from each of its ends.

FIELD OF THE INVENTION

The present invention relates generally to the field of window coveringsizing machines and more particularly to a blind and shade cuttingcenter.

BACKGROUND OF THE INVENTION

Mass retail merchandisers sell a large number of window coveringsdirectly to consumers. Standard sized window coverings are sized to aconsumer's specifications while the consumer waits. The apparatusemployed to size the various window coverings should be both easy to useby an employee of a retail outlet and should not require an extensivetraining period.

Additionally, the floor space that the cutting apparatus requires shouldfit within the existing structure and layout of the retail outlet.Further, the cutting apparatus ideally should size a number of differenttypes of window coverings, such as metal or vinyl mini-blinds, verticalblinds, pleated shades, and cellular shades.

Various attempts have been made to integrate various window coveringcutting mechanisms into a single multi-station system. One example of amulti-station system is disclosed in U.S. Pat. No. 5,456,149 toElsenheimer et al. entitled “Sizing System for Window Coverings” issuedOct. 10, 1995. The '149 patent discloses a station having a flip-topsurface including a pleated shade sizing station on one side and amini-blind sizing station on the other. This system minimizes the spacerequired by the merchandiser to cut various window covering products.This allows the retail outlet to include other stock and products inspace otherwise occupied by various window covering sizing equipment.

Recently more retail merchandisers utilize 8-foot bay spacing to displayand sell various products. Accordingly, a shade and blind cutting centerthat can be located within the 8-foot bay environment is needed.

The sale of vertical blind products has also increased through massmerchandiser retail outlets, requiring the ability to size not only thewidth of the vertical blind head rail but also the length of thevertical blind slats. However, if a cutting apparatus is to be locatedwithin an 8-foot bay environment, any vertical blind slat extendinggreater than 8 feet would not be able to be sized with an apparatuslocated within the 8-foot bay. Accordingly, there is a need for avertical blind cutting apparatus that would fit within the 8-foot bayenvironment as well as be able to size vertical blind slat producthaving a length greater than 8 feet.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention will become more fully understood from the followingdetailed description, taken in conjunction with the accompanyingdrawings.

FIG. 1 is a perspective view of the apparatus located in a bay in astored position.

FIG. 2 is a perspective view of the cutting apparatus of FIG. 1 in anoperating position.

FIG. 2 a is a front view of the cutting apparatus of FIG. 1 with thefront panels and the cutting motor removed.

FIG. 3 is a cross-sectional view of the apparatus taken generally alonglines 3—3 of FIG. 1, detailing the vacuum motor and detachable bag.

FIG. 3 a is a front detail view of the detachable vacuum bag, takenalong line 3 a—3 a of FIG. 2 a.

FIG. 3 b is a front detail view of the detachable vacuum bag, takenalong line 3 a—3 a of FIG. 2 a, with the vacuum hose hinged away fromthe bag.

FIG. 4 is a top plan view of the apparatus of FIG. 2

FIG. 5 is a top partial view of the area taken generally along lines 5—5of FIG. 4.

FIG. 6 is a cross-sectional view of the locator pin taken generallyalong lines 6—6 of FIG. 5.

FIG. 7 is a cross-sectional view of the die assembly of the firstcutting station taken generally along lines 7—7 of FIG. 4.

FIG. 8 is a cross-sectional view of the die and blade mechanism of thefirst cutting apparatus taken generally along lines 8—8 of FIG. 4.

FIG. 9 is the die and blade portion of the first cutting apparatus ofFIG. 8 in the fully extended cutting position.

FIG. 10 is a cross-sectional view of the blade and die apparatus of FIG.8 taken generally along lines 10—10 of FIG. 8.

FIG. 11 is a cross-sectional view of the cutting mechanism takengenerally along lines 11—11 of FIG. 8.

FIG. 12 is a cross-sectional view of the second cutting station takengenerally along lines 12—12 of FIG. 4.

FIG. 13 is a view of the head rail cutting mechanism with the die in theraised position.

FIG. 14 is a view of the head rail cutting mechanism die cutter in theraised position with the punch mechanism fully extended.

FIG. 15 is a cross-sectional view of the cutting apparatus takengenerally along lines 15—15 of FIG. 12.

FIG. 16 is a cross-sectional view of the cutting mechanism takengenerally along lines 15—15 of FIG. 12 in the extended cutting position.

FIG. 17 is a cross-sectional view of the apparatus taken generally alonglines 17—17 of FIG. 4.

FIG. 18A is a partial cross sectional view of the first cutting stationin the lower position.

FIG. 18B is a partial cross sectional view of the first cutting stationin the upper position.

FIG. 19 is a cross-sectional view taken generally along lines 19—19 ofFIG. 18A.

FIG. 20 is an exploded perspective view of three locators, rail andscale.

FIG. 20 a is an isometric view of a first removable locator.

FIG. 20 b is an isometric view of a second removable locator.

FIG. 21 is a cross-sectional view of the apparatus of FIG. 20.

FIG. 22 is an exploded perspective view of the connector clip and headrail aperture.

FIG. 23 is an exploded perspective view of the connector clip of FIG. 22attached to the head rail aperture, and a portion of the locator.

FIG. 24 is a top partial view of the head rail and connector clippositioned by the locator.

FIG. 25 is a top plan view of the cellular blind head rail and bottomrail positioned in the first cutting station of FIG. 7.

FIG. 26 is a top plan view of the cellular blind shade materialpositioned in the first cutting station of FIG. 7.

FIG. 27 is a cross-sectional view of the measuring device extension.

FIG. 28 is a perspective view of the vertical slat clamp and woodenblind clamp.

FIG. 29 is a partial side view of the wooden blind clamp.

FIG. 30 is an isometric of the vertical slat clamp.

FIG. 31 is an isometric view from the rear of the inside of the machine,detailing the dust collection system.

FIG. 32 is an isometric view from the front of the inside of themachine, detailing the dust collection system with the particulate binremoved.

FIG. 33 is an isometric view from the rear of the inside of the machine,detailing the cutting system with the dust collection system removed.

FIG. 34 is a perspective view from the front of the inside of themachine, detailing the cutting system.

FIG. 35 is an end view of the machine from the left side, detailing thecutting system and surface.

FIG. 36 is a cross-sectional view of the work surface taken along line36—36 in FIG. 2.

FIG. 37 is an isometric view of a die block with a movable bottom die.

FIG. 38 is a cross-sectional view of the die block of FIG. 37, takenalong line 38—38 in FIG. 37.

DETAILED DESCRIPTION

An apparatus for sizing both blinds and shades for window coverings isgenerally illustrated in FIGS. 1 and 2. The blind and shade cuttingcenter 10 is slidably movable on rails 12 in and out of a bay 14. Thecutting center 10 includes a first cutting station 16 for sizingmini-blinds, pleated shades, and cellular shades. The cutting centerfurther includes a second cutting station 18 for sizing wooden blindsand vertical blinds. The first and second cutting stations 16, 18 aresupported by and located on opposing ends of a housing 20. A controllermechanism 22 allows an operator to gain access and to control the firstand second cutting stations 16, 18. Further, cutting center 10 includesa center locating and measuring system 24 to position the blinds andshades to be sized.

Referring to FIGS. 2, 2 a, and 3 the housing 20 of the cutting center 10includes a bottom 26, a front wall 28, a first and second side wall 30,32, a rear wall 34, and a top working surface 36. The front wall 28includes a first panel 300 and a second panel 302 fastened to thehousing 20. The first panel 300 includes an opening 304.

The second panel 302 includes a first door panel 306, a second doorpanel 308, and a secured panel 310. The first and second door panels 306and 308 are hingedly connected to the secured panel 310. The securedpanel 310 is securedly fastened to the housing 20, while the first andsecond door panels 306 and 308 are releasably fastened to the housing20.

Located inside the cutting center 10 and behind the front wall 28 is aninterior 29 divided into a series of chambers. Closest to the secondside wall 32 is a refuse chamber 312. The cutting center 10 furtherincludes a cutting motor chamber 314, a vacuum chamber 316, a hydraulicschamber 318, a bar code scanner chamber 320, and an electronics chamber322, wherein there is disposed a controller 323. The cutting motorchamber 312 and the vacuum chamber 316 are separated by a divider 315.The refuse chamber 312 and the vacuum chamber 316 are accessible byopening the first and second door panels 306 and 308, respectively. Thebar code scanning chamber 320 is accessible through the opening 304 inthe first panel 300.

For purposes of this application the cross-housing direction is definedas the direction that is perpendicular to the front wall 28 and rearwall 34. Similarly, the longitudinal direction will be defined as thedirection that is perpendicular to the first and second side walls 30,32. The right side of the housing 20 will be defined from theperspective of an operator as they face the bay 14. Accordingly, thefirst side wall 30 is on the right side of the housing, while the secondside wall 32 is on the left side of the housing. The longitudinal axisof the housing will be defined as an axis extending centrally on the topworking surface 36 and perpendicular to the first and second side walls30, 32. The cross-center axis will be defined as an axis extendingcentrally on the top working surface 36 and parallel with thecross-housing direction. The cross-center axis is perpendicular to thelongitudinal axis.

The housing 20 may be moved from a stored position (as illustrated inFIG. 1) in which the housing 20 is located within the bay 14 to anoperating position (as illustrated in FIG. 2) in which the housing 20 islocated substantially outside of the bay 14. The stored position permitsthe housing to be completely out of the aisle of a retail or massmerchandising outlet. In the operating position, the housing isaccessible for an operator to size a blind or shade product as will bedescribed below. While it is possible to size a blind or shade productwhile the housing is in the stored position, the length of the productto be sized may be limited by the size of the bay.

The bay 14 typically includes a front surface 38 and a first and secondside support 40, 42. The supports 40, 42 may be in the form of a wall ormay be in the form of a frame. When the housing 20 is in the storedposition, the front wall 28 may be flush with the front surface 38 ofthe bay or may be located a distance within the bay from the aisle toensure that no part of the cutting center 10 protrudes into the aisle.Further, if the cutting center 10 is completely located within the bay14, the possibility of it being damaged by a forklift or customer cartsis minimized.

The housing 20 may include a handle or handles (not depicted) tofacilitate sliding the cutting center 10 in and out of the bay 14 on therails 12. All of the equipment employed in the cutting center 10 isattached to the housing 20. The depth of the housing 20 as measured inthe cross-housing direction can be less than the depth of the bay 14.

As will be described below, an exemplary cutting center 10 includes acenter locating and measuring system as well as an end locating andmeasuring system. Both systems allow the operator to size a blind orshade by referring to only the customer's specification of the finalsize and length of the blind. In contrast, other sizing methods requiredthe operator to calculate the amount of material to be removed from eachside of the blind and locate the blind relative to the sizing stationaccordingly. This may lead to errors in the final product, resulting inboth scrap material as well as a delay in the time it takes to deliver afinal sized product to the consumer.

The center locating system positively locates the center of the blind tobe sized, while the end locating system locates the shade relative toone end of the shade. Where the lift cords are visible to the consumersuch as in a Venetian blind or a pleated shade it is important that thelift cords remain symmetrical about the center of the blind. The centerlocating system employs a half scale that permits an employee to sizethe blind by referring to only the customer's final width of the blind.In contrast, the end locating system may be used for cellular shadeswhere the lift cords are hidden from view and it does not matter thatthe lift cords are not symmetric about the center of the shade.Similarly, the end locating system may be used for a vertical blind headrail and vanes where the products may be sized from a single end.

Referring to FIGS. 4, 20 and 21, the pin locator 48, the center cliplocator 50, and the end locator 52 are illustrated. Each locator 48, 50,52 is attached to a respective carriage 54 having a plurality of rollers56 that are slidably received in a rail 58. The rail 58 extendsproximate the front wall 28 of the housing 20 and parallel to thelongitudinal axis of the housing 20. The rail 58 and carriage 54 deviceis available commercially and marketed under the trade mark Redi Rail™.The pin locator 48 and the center clip locator 50 illustrated in FIG. 20are center locating devices that positively locate the center of theblind or shade to be sized. The end locator 52 is a locating device thatis used to both square the blind or shade and to locate certain blindand shade products relative to one end of the blind.

The pin locator 48 and the center clip locator 50 both permit a blind tobe sized from its center by engaging a center portion of the blind. Thepin locator 48 includes an extension member 60 attached to the carriage.A pointer 68 is attached to the carriage 54 and indicates that positionof the pin locator 48 relative to the first or second cutting stations16, 18 by use of a scale as discussed below. The extension 60 extends inthe cross-housing direction from the carriage 54 toward the rear of thetop working surface 36. A first pin 62 extends from the carriage 54parallel with the top working surface 36 of the housing 20 and towardsthe rear wall 34. The first pin 62 is located a predetermined distanceabove the top working surface 36. A second pin 64 may extend from therear portion 66 of the extension 60 toward the front wall 28 apredetermined distance above the top working surface 36.

Pins 62 and 64 each have a cross section that corresponds to the crosssection of an aperture in the bottom rail of the shade or blind. In theexample illustrated in FIG. 6, the pin 62 has a cross-shaped crosssection. However, any other shape may be employed as well, for example around cross section may be used. Pin locator 48 includes a pointer 68that identifies the location of the pins 62, 64 relative to the firstscale 70.

The center clip locator 50 is illustrated in FIGS. 4 and 20. The centerclip locator 50 includes an extension 72 attached to the carriage 54 forslidable movement in the rail 58. A pointer 74 is attached to the centerclip locator 50 that identifies the position of the locator relative toa second scale 76. The extension 72 of the center clip locator 50includes a slot 78 having a width configured to receive and positivelylocate a center clip 80 attached to the center portion of the blind headrail or bottom rail (See FIG. 22.).

Referring to FIGS. 22 and 23, the center clip 80 is positively securedto a head rail 82 or bottom rail by positive location of a protrusion 84of the center clip with an aperture 86 or other locating device in thecenter of the head rail 82. Alternatively, the center clip 80 couldinclude an aperture that is positioned relative to a detent or tablocated on the head rail. Further, any other mechanical means oflocating the center clip 80 onto the head rail may be employed. Thecenter clip 80 may be made of a resilient material such that the centerclip 80 may simply be located in the center of the blind head rail priorto sizing and maintained in place by the spring force of the center clip80.

As illustrated in FIG. 4, the pin locator 48 is positioned on the rightside of the cutting center 10 and the center clip locator 50 ispositioned on the left side of the cutting center 10. However, thisorientation is for illustration purposes only. It is possible thatcutting center 10 includes two pin locators 48 on both the right andleft sides of the cutting center or two center clip locators 50 on boththe right and left sides of the cutting center 10. Any combination oflocators 48, 50 may be employed depending on the type of locating systemthat is used to locate the actual products to be sized.

The pin locator 48 as illustrated in FIG. 4 is slidably positionedrelative to a cutting plane 88 (See FIGS. 10 and 11) of the firstcutting station 16 by the first scale 70. The first scale 70 is locatedon the right side of a raised portion 90 proximate the rail 58 (FIG.20). Similarly, the center clip locator 50 is slidably positionedrelative to the cutting plane 92 (See FIG. 15) of the second cuttingstation 18 by the second scale 76.

The first and second scales 70, 76 each include half scale indicia andextend proximate the front edge of the top working surface and parallelto the longitudinal axis. The first and second scales 70, 76 includehalf scale indicia where each unit of measurement is identified as twiceits actual distance from the cutting planes of the first and secondcutting stations respectively. For example, a distance of fifteen inches(15″) from the cutting plane 88 of the first cutting station 16 isidentified as thirty inches (30″) on the half scale indicia.

The half scale indicia allows an employee or operator to size a windowblind by only knowing the final desired width of the window blind. Thewidth of the window blind is defined as the horizontal distance betweenthe two sides of the window blind when the window blind is installedrelative to the window or opening to be covered. The height of thewindow blind is the vertical distance that the window blind or shadecovers. The term “length” as it is used in conjunction with the Venetianwindow blind head rail, slats or bottom rail will correspond to thewidth of the window blind.

Referring to FIGS. 4 and 20, an end locator 52 includes an extension 94attached to carriage 54 for translation along rail 58. The extension 94extends from the carriage 54 in the cross-housing direction and includesa first side 96 and a second side 98 parallel to the first side 96. Thefirst side 96 faces the first cutting station 16 while the second side98 faces the second cutting station 18. As will be described below thefirst and second sides 96, 98 of the extension 94 extend a sufficientdistance from the top support surface 36 to engage the ends of the blindor shade to be sized to help align the head rail, bottom rail and windowcovering material for sizing. Further, the first side 96 is also used tolocate the cellular shade as will be described below. The end locator 52further includes a set block 100 extending from the first side 96 a setdistance toward the first cutting station 16. The end locator 52 furtherincludes a cut out region or a depression 102 in the top portion of theextension 94 that permits a portion of the cellular window coveringmaterial of the cellular blind to extend through the extension 94 whenthe head rail and bottom rail are being sized. The end locator 52 ispositioned between pin locator 48 and center clip locator 50, which inthis example are on the right and left side of the cutting center,respectively and is illustrated in FIG. 4. Of course, as noted above,either the pin locator 48 or center clip locator 50 may be disposed onthe right side or the left side of the cutting center 10.

It is possible that by placing the end locator 52 to the extreme leftend of the work surface 36 to size a blind using the first cuttingstation 16, or vice versa, there still might not be enough room on thework surface 36 to size a large blind. To gain several inches of worksurface 36, the end locator 52 includes a hinge near the carriage 58,such that it can be flipped up and moved out of the way (see FIG. 2).Further, first and second removable locators 53 and 55 (see FIGS. 20 aand 20 b) are placed near the ends of the work surface 36 and areadapted to be fitted to the pin locator 48 and the center clip locator50 such that the removable locators 53 and 55 perform the function ofthe end locator 52.

The first removable locator 53 includes a first side 96 with a set block100 and a depression 102 the same as the first side 96 of the endlocator 52 and is used to locate a blind relative to the first cuttingstation 16. By placing the first removable locator 53 in the left mostlocator, in this example the center clip locator 50, and flipping theend locator up as in FIG. 2, an additional 3–5″ of work space may begained. The first removable locator 53 can locate a cellular shade, ametal shade, or a vinyl shade, for sizing on the first cutting station16 in the same manner as the end locator 52.

The second removable locator 55 includes a second side 98 as in the endlocator 52, however, it does not include a depression 102 because nocellular shade are sized using this locator 55. Its operation is similarto the first removable locator 53, however it is placed in the locatoron the right side of the cutting center 10, in this example the pinlocator 48, as it is used to size blinds being cut on the second cuttingstation 18.

Referring to FIGS. 7–10, first cutting station 16 will be described infurther detail. First cutting station 16 includes a stationary die 104and a moveable die 106 slidably coupled to the stationary die 104. Aguiding die member 108 is secured to a first face 110 of stationary die104 to provide a plurality of beveled or flared surfaces 112 for guidingthe various bottom rails, slats and head rails of the blinds and shadesto be sized into openings in the stationary and movable dies 104, 106.

Referring to FIG. 8, the stationary die 104 includes three regions forcutting three different types of window covering products. The firstregion 114 is configured for sizing a mini-blind product having metal oraluminum slats and a metal head rail and bottom rail. This mini-blindproduct will be referred to as the metal mini-blind product. Firstregion 114 of the stationary die 104 includes a first channel 116 forreceiving a bottom rail of a mini-blind product, and an opening 118 forreceiving a plurality of metal or aluminum slats from the metalmini-blind product. Further, first region 114 of stationary die 104 alsoincludes a second channel 120 for receiving the head rail of the metalmini-blind product.

Additionally, stationary die 104 includes a second region 122 for sizinga mini-blind having a plurality of vinyl slats. This mini-blindconfiguration will be referred to as a vinyl mini-blind product. Thissecond region includes a channel 124 for receiving the bottom rail of avinyl mini-blind product having vinyl slats and a second opening 126 forreceiving the vinyl slats, and finally a third channel 128 for receivingthe head rail of the vinyl mini-blind product.

The third region 130 of stationary die 104 is for sizing a pleated orcellular shade and includes a first pair of channels 132, 134 forreceiving the ends of a head rail and bottom rail from a pleated orcellular shade. Similarly, third region 130 may include a second pair ofchannels 136, 138 for receiving the second ends of the head rail andbottom rail from a pleated or cellular shade, when the head rail andbottom rail are not symmetric. However, in the preferred embodiment, thehead rail and bottom rail are symmetric and therefore only a single pairof channels is required. Accordingly, the second pair of channels 136,138 is shown in phantom lines. The third region 130 also includes anopening 140 for receiving the pleated or cellular material to be sized.

Referring to FIG. 9, the movable die 106 similarly has three regionsthat correspond with the respective three regions of the stationary die104. The first region 142 of the movable die 106 includes a first dieopening 144 to receive both the portion of the bottom rail and metalslats of the metal mini-blind to be sized. A first blade 146 is attachedto the movable die 106 and separates the first die opening 144 from asecond die opening 148 that receives the portion of the head rail to besized. The first blade 146 is fastened to the movable die and includes acutting surface 150 that is proximate the stationary die 104. Firstblade 146 cuts both the metal slats and the bottom rail. The geometry ofthe first blade 146 permits the metal slats and bottom rail to be sizedwith the same blade without the blade chipping when it cuts the bottomrail member. First blade 146 has an arcuate surface that corresponds toan arcuate portion on the outer surface of the stationary die 104.However, other known cutting shapes may also be employed.

The second region 152 of the movable die 106 is located below the firstregion 142. The second region 152 includes a first opening 154 toreceive both the portion of the bottom rail and vinyl slats of a vinylmini-blind to be sized. A second blade 156 is attached to the movabledie 106 and separates the first opening 154 from a second opening 158that receives the portion of the vinyl mini-blind head rail to be sized.The second blade 156 is fastened to the movable die 106 and includes asharpened edge 160 that is proximate the stationary die 104.

The third region 162 of the movable die 106 is situated in line with thefirst region of the movable die such that it corresponds to the thirdregion 130 of the stationary die 104. The third region 162 includes afirst opening 164 and a second opening 166. A shearing portion 168 islocated proximate the first opening 164 and a shearing portion 170 islocated proximate the second opening 166. However, a single opening andshearing portion may also be used.

Finally, the third region 162 of the movable die includes a thirdopening 172 for receiving the cellular or pleated shade material to besized. A blade 174 is attached to the movable die 106 and has a bladeedge 176 to cut the cellular and pleated material as the movable die 106is moved from a retracted position illustrated in FIG. 8 to the fullyextended position illustrated in FIG. 9.

As illustrated in FIGS. 17, 18 a, and 18 b the stationary and movabledies 104, 106 are attached to a frame 178 that is movable from a firstposition in which the first regions 114, 142 and third regions 130, 162of the stationary and movable dies 104, 106 are proximate the topworking surface 36 of housing 20, to a second position in which thesecond regions 122, 152 are proximate the top working surface 36.Further the frame 178 may be moved to a third position in which theentire first cutting station 16 is lowered to a position below the topworking surface 36 to facilitate the sizing of vertical blind slatshaving a length greater than the width of the housing 20.

When the entire first cutting station 16 is lowered to a position belowthe top working surface 36, an extension scale 180 may be attached tothe housing (See FIG. 27). A vertical peg 182 fastens the extension tothe housing 20 so that the extension scale 180 remains in a planeparallel with the top working surface 36. This feature allows a simpledisassembly upon raising the first cutting station 16 and also allowsthe extension scale 180 to slip out of its position on the housing ifthe first cutting station 16 is raised without first removing theextension scale 180. Further, if the housing is moved back into the baybefore removing the extension scale 180, the scale will simply pivotabout the peg 182 to prevent damage to the extension scale 180 or to thehousing.

In the preferred embodiment, the frame is moved between the first,second and third positions with a hydraulic piston 184 that iscontrolled by the controller 22. The hydraulic piston 184 is shown inFIGS. 17, 18 a and 18 b.

In an alternative manual embodiment illustrated in FIG. 19, a springbiased release mechanisms 186 is located on each side of the frame 178to releasably secure the frame in the first, second or third positions.Each release mechanism 186 includes a spring biased button 188, eachhaving a spring member 190 biasing a pin 192 into engagement with one ofthree pairs of support members 194 attached to housing 20. By manuallypulling the engaged pair of buttons 188 in an outward direction, thepins 192 are released from the support member 194 and the frame 178 maybe moved upward or downward to another one of the pair of supportmembers. In this manner, the first cutting station 16 may be movedmanually between the first, second and third positions.

Inside the bar code scanner chamber 312 is disposed a bar code scanner324. The bar code scanner 324 is accessible by the user from the frontof the cutting center 10 through the opening 304. The bar code scanner324 is of standard construction. The scanner 324 is used to allow accessto the cutting center 10 by a user and automatically configure thecutting center 10 based on the code of a blind scanned in. First, theuser must scan the code on his or her own personal identification card.This card can be issued when the user has completed a certificationcourse. Thus, the scanner 324 only allows employees trained in itsoperation to use the cutting center 10. By scanning in a user ID card,the cutting center 10 is enabled, and the user may then proceed. Next,the user scans the bar code associated with a blind product. If theblind to be cut is associated with the first cutting station 16, thesecond cutting station 18 is disabled, and the first cutting station isenabled. Further, if the blind to be cut is associated with the firstcutting station 16, the stationary and movable dies 106, 108 are raisedor lowered to accommodate the style of blind to be cut. In this example,if a metal blind is to be cut, the stationary and movable dies 106, 108are moved to the first position.

The method for sizing a metal mini-blind product utilizing the cuttingcenter 10 will now be described in detail. As discussed above, thecutting center 10 can cut more than one type of mini-blind or shadeproduct. The first cutting station 16 includes two different regions forcutting two different types of mini-blind products. The mini-blindproducts could have different geometry necessitating different dieopenings, and/or different shearing configurations, and/or differentblade combinations. In the example illustrated in the figures the firstcutting station 16 permits the sizing of two different mini-blindproducts formed of different material and having a different geometry.In the preferred embodiment, the first regions 114, 142 of thestationary and movable dies 104, 106 of the first cutting station 16 areconfigured to size a metal mini-blind product having a metal bottomrail, a metal head rail and aluminum slats. The second regions 122, 152are configured to size a vinyl mini-blind product having vinyl slats.

A customer will measure the width of the window or windows to be coveredand bring this dimension to a retail outlet to purchase a mini-blindproduct. If the mini-blind product in stock does not match thedimensions required by the customer, an employee/operator will size astock size mini-blind product to the customer's specified dimension.This system only requires that the operator select the stock mini-blindproduct having a width greater than that required by the customer. Theoperator, as will be described herein, does not need to calculate thedifference between the stock product and customer's dimensions, nor doesthe operator need to divide the difference between the stock mini-blindproduct and the customer's specifications. The operator will cut aportion of the head rail, bottom rail and window covering material fromeach end of the stock mini-blind product, without the need to know anyvalue but the customer's desired end width of the mini-blind. Byremoving material from both ends of the mini-blind product as describedbelow, each pair of lift cords will remain an equal distance from eachrespective end of the mini-blind.

Once the operator has identified and selected the stock mini-blindproduct closest to, yet wider than the customer's specification, thecutting center 10 is pulled from the stored position in bay 14 asillustrated in FIG. 1 to the extended position as illustrated in FIG. 2.The operator gains access to the center controls by scanning his or herunique identification card with the bar code scanner 324. This enablesthe cutting center and the control mechanism 196 requests the user toscan the blind to be sized. Alternatively, the user can enter his or heridentification number in the control mechanism 22, or any other way toenter a personal identification such as swiping a card, fingerprintscanning, etc. The control mechanism 22 may be connected to thecontroller 323 that identifies the operator seeking access to thecutting center 10. The controller 323 may also store the informationentered by the operator including the time of entry. The system mayfurther be programmed to record information relative to the stock blindbeing sized as a way of monitoring inventory. Additionally, the timerequired to size the mini-blind may be recorded. The bar code scanner324 has the added benefit of prohibiting unauthorized personnel fromaccessing the cutting center 10.

After the cutting center 10 has been activated by means of the bar codescanner 324, the operator then scans the UPC or bar code of the miniblind to be sized. Because a metal mini blind product is being sized inthis example, the stationary and movable dies 104, 106 are raised orlowered to the first position in which the first regions 114, 142 areproximate the top working surface 36 of the housing 20.

The operator then loads the stock mini-blind product onto the topworking surface 36. As discussed above, both the pin locator and centralclip locator for centrally locating the stock mini-blind to be sized maybe utilized. For illustration purposes only, the pin locator 48 will bedescribed for locating the mini-blind product relative to the firstcutting station 16 and the center clip locator 50 will be described forlocating the wooden mini-blind product relative to the second cuttingstation 18. However, the center clip locator 50 could be used to locatethe mini-blind product relative to the first cutting station 16 as well.

When using the pin locator 48, the bottom rail of each stock mini-blindproduct includes a centrally located aperture or opening through thebottom most portion of the bottom rail. The aperture could also be aslot extending perpendicular to the longitudinal axis of the bottomrail, or an indentation or depression or connector or any other meansfor centrally locating the mini-blind product. The aperture is centrallylocated in the bottom rail, however, the aperture or locating meanscould also be located in the head rail. The operator locates theaperture onto the pin 62 of the pin locator 48. The portions of thefirst end of the head rail bottom rail and slats that are to be cut offare slid through the first regions 114, 142 of the stationary andmovable dies 104, 106. The bottom rail is located in channel 116 of thestationary die 104 and opening 144 of the movable die 106. Similarly,the slats are located in opening 118 of the stationary die 104 andopening 144 of the movable die 106. Finally, the head rail is located inchannel 120 of the stationary die 104 and opening 164 of the movable die106.

The stock mini-blind product is positioned relative to the cutting plane88 of the first cutting center 16 by lining up the pointer 68 of the pinlocator 48 with the customer's specification on the half scale indiciaon the first scale 70. The half scale indicia is dimensioned relative tothe cutting plane 88 of the first cutting station 16 which is generallydefined by the outer surface of the stationary die 104 that determinesthe location of the sized end of the head rail, bottom rail and slatsafter the movable die 106 is activated and shears and/or cuts the headrail, bottom rail and slats. The half scale units are one half of theactual distance from the cutting plane. For example thirty (30) incheson the half scale is only one half of thirty (30) or actually onlyfifteen (15) inches from the cutting plane. Once the movable die 106 isactivated the newly cut ends of head rail, bottom rail and slats will be15 inches from the center aperture.

To activate the movable die 106 in the first cutting station 16, theoperator simultaneously depresses the two activation buttons. Themovable die 106 is moved from the rest position to the extended positionby a plunger 198 that is driven by a pneumatic or hydraulic cylinder200. The first blade 146 shears the slats and subsequently the bottomrail, while the shear portion of opening 148 shears the head rail. Ifthe operator releases the activation buttons during the cutting process,the movable die 106 will stop. This feature ensures that the operator'shands are safely away from the movable die 106 during the activationsequence. Once the movable die 106 is fully extended and the first endof the head rail, bottom rail and slats are sized, the movable die 106retracts to the rest position.

After the first side of the mini-blind product is sized, the operatorremoves the mini-blind product from the pin 62 and rotates it such thatthe sized end of the mini-blind product is away from the first cuttingstation 16. The center aperture on the bottom rail of the mini-blindproduct is once again located on the pin 62. Once the mini-blind hasbeen located, the movable die 106 is activated and the second side ofthe head rail, bottom rail and slats are sized. In this example thedesired width of the mini-blind product was thirty (30) inches. Sinceeach side of the blind was sized relative to the central locating holein the bottom rail, the cut ends of the mini-blind product are fifteen(15) inches from the center for a total mini-blind width of thirty (30)inches. In this manner the lift cords are equal distance from the centerof the mini-blind product and equal distance to their respective ends ofthe sized mini-blind product.

The sizing of the metal mini-blind occurs while the first cuttingstation 16 is in the first position relative to housing 20 as describedabove. A vinyl mini-blind is sized in a second position of the cuttingstation. To move the first cutting station 16 to the second positionutilizing the hydraulic piston, the operator scans the bar codeassociated with a vinyl mini-blind to move the first cutting station 16to the second position. In the alternative embodiment, the manualrelease mechanism 185 may be used to move the frame. The buttons 188 ofthe release mechanism are pulled outward releasing the pins 192 from thesupport members 194 thereby permitting the operator to move the firstcutting station 16 upward until the buttons are aligned with and engagedwith a second pair of support members 194. The steps for sizing thevinyl mini-blind in the first cutting station are the same as the stepsfor sizing the metal mini-blind as described above. However, the vinylmini-blind is sized in the second regions 122, 152 of the stationary andmovable dies 104, 106.

The process of sizing a pleated or cellular shade will now be described.The pleated material is sized independently of the bottom rail and headrail. The shearing portions 168, 170 of the third portion 162 of movabledie 106 that are used to size the bottom rail and head rail of a pleatedshade are not sharp enough to cleanly cut the material. The pleatedmaterial is sized in a separate step from the sizing of the head railand bottom rail utilizing a sharp blade 174. In a pleated blind the liftcords are visible and therefore it is desirable to have the pair of liftcords be symmetrical with respect to the center of the pleated blind.Accordingly, the pleated blind may be sized in four distinct steps.First one end of the head rail and bottom rail are sized to the finalwidth of the pleated shade. Second, one end of the pleated material issized. Third, the other end of the head rail and bottom rail is sized.Fourth, the other end of the pleated material is sized.

The steps for removing the cutting center 10 from the bay 14, andaccessing the cutting center 10 is the same as that described above forsizing the mini-blind products. Additionally, the first cutting station16 is moved to the first position to size the pleated shade product.This is the same position as when the metal mini-blind product is beingsized.

As with the mini-blind products discussed above, the bottom rail of thepleated shade includes an aperture which is located on pin 64 of pinlocator 48. In contrast to the front pin 62 utilized to locate themini-blind products, the rear pin 64 is utilized to locate the pleatedor cellular shade. By using the half scale indicia of the first scale70, the pin locator 48 is aligned with the finished dimension of thecustomer's specification.

The first end of the head rail and bottom rail are slid into channels132, 134 respectively and openings 164, 166 of the movable die 106. Thepleated material however, is not slid into any opening at this time, butrather the pleated material is slid relative to the bottom rail and headrail, so that one end of the pleated material extends past the secondend of the head rail and bottom rail. The first cutting station 16 isactivated as discussed above with respect to the mini-blind products.

After the first ends of the pleated head rail and bottom rail are sized,the pleated material is slid into openings channels 132, 134 of thestationary die 104 and openings 164, 166 of the movable die 106. Thedimension of the guide die plate 108 proximate opening 140 does notpermit the head rail and bottom rails to pass into opening 140 and isstopped a predetermined distance from the cutting plane. In thepreferred embodiment, the distance from the ends is one inch. The endlocator is used to size the pleated material. The end locator set block100 received between the pleated shade bottom rail and head rail suchthat the set block 100 pushes the pleated material forward of the sizedend of the bottom rail and head rail a predetermined distance. In thepreferred embodiment, the set block extends one inch from the first sideof the end locator extension to compensate for the one inch distance thebottom rail and head rails are short of the cutting plane 88. In thismanner when the pleated material is sized by blade 174 the width of thepleated material is the same as the width of the head rail and bottomrail.

The process is repeated on the second ends of the pleated shade headrail, bottom rail and pleated material. Where the head rail and bottomrail are not symmetric the second ends of the head rail and bottom railwill not fit in channels 132, 134. The second ends of the head rail andbottom rail must be inserted into channels 136, 138 respectively, thatare configured to accommodate the different orientation of the secondends of the pleated shade bottom rail and head rail.

Alternatively, the stock pleated shade product may be sized in threesteps. First the head rail and bottom rail may be sized by cuttingmaterial off from a single end to the final width of the customer'sspecification. Since the head rail and bottom rail are being sized fromone end only, a full scale may be utilized to locate the head rail andbottom rail relative to the cutting plane. The pleated material is thencut equally on both sides in two separate cutting operations so that thelift cords remain symmetric about the center of the head rail and bottomrail.

Referring to FIGS. 25 and 26, the sizing of the cellular product in twosteps is illustrated. In the first step the entire portion to be removedfrom the stock cellular head rail and bottom rail is removed in a singleoperation of the movable die 106. Accordingly, the cellular shade may belocated relative to a cellular scale 202 having full scale indicia suchthat the markings on the scale 202 reflects the actual distance from thecutting plane 88. The end locator 52 is utilized to locate the cellularproduct to be sized. The head rail and bottom rail of the cellularproduct are inserted into channels 132, 134 while the other ends of thehead rail and bottom rail that are not to be sized are located againstthe first side of the end locator 52. The first side of the end locator52 is aligned with the full scale indicia of scale 202 corresponding tothe actual width of the blind as requested by the customer. When thehead rail and bottom rail are being sized the cellular material is slidaway from the ends of the blind to be cut off and towards the secondcutting station 18. The cellular material is allowed to pass through endlocator 52 extension 94 via opening 102.

Once the head rail and bottom rail have been cut to size, the cellularmaterial is slid past the newly cut ends of the head rail and bottomrail into openings 140 and 172 of the stationary and movable dies 104,106 respectively. The end locator set block 100 pushes the cellularmaterial the required distance into the first cutting station to ensurethat the cellular material will have the same width as the head rail andbottom rail once it is sized. The set block 100 is utilized the same wayfor the cellular material as for the pleated material discussed above.

Referring to FIGS. 12–16 the second cutting station 18 includes avertical head rail shearing mechanism 204 and a wooden blind sizingmechanism 206. Vertical shearing mechanism 204 includes a stationary die208 having a channel 210 for receiving a head rail of a vertical blindproduct. The stationary die 208 includes a second opening 211 forreceiving the traverse rod of the vertical blind product. A movable die212 moves relative to the stationary die 208 in a vertical up/downdirection. Movable die 212 includes a shearing portion 214.Additionally, vertical shearing mechanism 204 includes a punch 216 thatpunches a hole in the base of the vertical blind head rail a setdistance from the cut end of the head rail as described below. Avertically oriented piston 217 moves the movable die 212 upward anddownward as illustrated in FIGS. 13 and 14 respectively.

Turning to FIGS. 12, 15 and 16, the wooden blind sizing mechanism 206includes a circular saw 218 having a circular blade 220 that moves froma first position proximate the rear wall 34 to an extended position inthe cross housing direction toward the front wall 28. In this example,the circular blade is an Irwin Marathon 10 inch, 80 tooth blademanufactured by American Tool, Part No. 14076.

As has been described, the center clip locator 50 slides along the topof the work surface 36 in the longitudinal direction. As seen in FIG.36, the center clip locator 50 has a top surface 51 that supports ablind B to be sized, and a thickness t, in this example ¼″. The secondcutting station 18 includes a plate 326 with a top surface 328 whichsupports the blind B as it is being sized. To compensate for thethickness of the center clip locator 50, the plate 326 is disposed suchthat its top surface 328 is coplanar with the top surface 51 of thecenter clip locator 50. Thus, in this example, the top surface 328 ofthe plate 326 is ¼″ higher than the working surface 36.

Turning now to FIGS. 33 and 34, the cutting motor chamber 314 can beseen, with the vacuum system removed for clarity. The saw 218 is movedtranslationally along a rail system 330 by a servo drive motor system332. A support plate 334 is securely fastened to the housing 20 withinthe cutting motor chamber 314. Two guide rails 336 are securely mountedto the support plate 334 such that they are perpendicular to thelongitudinal axis of the machine. Slide rails 338 are translationallymounted to the guide rails 336 such that they slide relative to theguide rails 336. A motor plate 340 is securely mounted to the sliderails 338, with the saw motor 342 fastened to the motor plate 340.

Fastened to and extending up from the motor plate 340 is a saw plate344. The saw plate 344 includes a bearing in which an axle 346 isplaced. The axle 346 includes a gear 348 on one end that is connected tothe saw motor 342 through a belt 350. Connected to the other end of theaxle 346 is the saw blade 220. The rotation of the circular saw blade220 is driven by the saw motor 342 connected through the belt 350. Theservo motor 332 drives the wooden blind sizing mechanism 206 such thatthe saw blade 220 is moved along a cutting path that is perpendicular tothe longitudinal axis of the cutting center 20 as can be seen in FIGS.12, 15, and 16.

Turning to FIG. 35, the cutting path 92 is defined by a slit 352 in theplate 326. The saw blade 220 includes an upper portion 354 above theplate 326 where the cutting action takes place, and a lower portionbelow the plate 326. The plate 326 is adapted to support a blind whilethe saw blade 220 traverses the cutting path 92 through the slit 352 inthe plate 326 and sizes the blind. Large pieces that are cut off fromthe blind fall through an opening 355 in the plate 326 and into a refusebin 356 in the refuse chamber 312 (see FIGS. 2 and 2A), while smallparticulate and dust get sucked through the slit 352 into a vacuumsystem as will be described later.

The servo drive motor allows the translation of the saw blade 220 alongthe cutting path at different speeds. In one example, the translationhas three speed stages. In the first stage, or ramping stage, the sawblade 220 is accelerated, or ramped up to its translational cuttingspeed. In the second stage, the saw blade 220 is translated at itscutting speed in which the blind to be sized is cut. After the cut iscomplete, the saw blade 220 is translated back to its home position in athird stage, or return stage at a speed faster than the cutting speed.By including an increased speed during the return stage, the cycle timemay be decreased significantly.

The plate 326 further includes at least one sensor 358 that is adaptedto detect steel. The saw blade 220 is chosen such that it effectivelycuts wood and plastic blinds, as well as the aluminum head-rails.However, the saw blade 220 can be damaged by cutting through a steelhead rail. Thus, if the sensor 358 determines that a steel head rail hasbeen placed in the cutting path 92, the sensor 358 sends a signal to thecontroller 323 which then disables the second cutting station 18. Inthis manner the saw blade 220 is protected.

The second cutting station 18 also has a dust and particulate collectionsystem 360 that will now be described as seen in FIGS. 3, 3 a, 3 b, 31and 32. The dust collection system 360 is disposed in the cutting motorchamber 314 and the vacuum chamber 316. Attached to the motor plate 340is a sheath 362 that surrounds the portion of the saw blade 220 that isbeneath the plate 326. Also attached to the motor plate 340 is aparticulate bin 364. The particulate bin 364 and the sheath 362 areconnected in an air-tight fashion. The particulate bin 364 includes acap 366 and a body 368, wherein the body 368 is removable from the cap364 and is attached to the cap via slide rails 370 and a locking lever372. Connected to the cap 366 of the particulate bin 364 is a flexiblehose 374, which is in turn connected a vacuum motor 376. The flexiblehose is preferably as large as possible, in this example, 2″ indiameter. The vacuum motor 376 is securely fastened to the housing 20,and in this example it is adjacent the rear wall 34. Since the vacuummotor 376 is stationary and the particulate bin 364 moves with thewooden blind sizing mechanism, the flexible hose 374 can be disposed ina loop 378, as shown in FIGS. 31 and 32 to accommodate the relativemotion between the particulate bin 364 and the vacuum motor 376. Thevacuum motor 376 should be sized to be powerful to ensure that the greatmajority of dust is pulled through the saw into the dust and particulatecollection system. Because this vacuum motor 376 is only provided with3″ ports, adapter cones (not shown) have been added have connect the 2″hose to the 3″ ports. Alternatively, 3″ hoses may be used.

The vacuum motor 376 expels the debris into and through a secondflexible hose 380 which leads forward toward the front wall 28 to avacuum bag 382. As seen in FIGS. 3, 3 a and 3 b, the second flexiblehose 380 terminates in an elbow 384 which is attached to a mountingplate 386. The elbow 384 protrudes a small distance beyond the mountingplate 386 into the vacuum bag 382. The mounting plate 386 is attached toa securing plate 388 via a spring loaded hinge (not shown). The securingplate 388 includes a groove 390 into which is fitted a lug 392 of thevacuum bag 382. In this manner, to remove the vacuum bag 382 fordisposal, the user may simply lift the mounting plate 386 such that theelbow 384 is fully removed from inside the vacuum bag 382, then slidethe vacuum bag 382 forward out of the housing 20, the lug 392 slidingthrough the groove 390.

As described earlier, the large pieces cut from the blinds fall from theend of the plate 326 into a refuse bin 356. To empty the refuse bin 356,the user opens the first door panel 306 and pulls out the refuse bin356. Smaller particulate and dust, however, get sucked into the vacuumsystem 360 down through the sheath 362 by the vacuum motor 376.

A clearance is built into the slit 352 in the plate 326 such that thereis adequate space between the saw blade 220 and the slit 352 that enoughair flow can be directed through the slit 352 and into the vacuum systemto ensure that the great majority of dust is pulled into the vacuumsystem. In this example, the slit 352 is approximately ½″ wide.

Due to the clearance between the slit 352 and the blade 220, pieces thathave been cut off up to approximately ½″ can be sucked into the vacuumsystem 360. If these pieces were to enter the vacuum motor 376, themotor would most likely suffer damage. To ensure that no large particlesbecome sucked into the vacuum motor 376, the particulate bin 364 isprovided. Any large particles that get pulled down through the sheath362 enter into the particulate bin 364. Because the flexible hose 374leading to the vacuum 376 motor is disposed in the cap 366 of theparticulate bin 364, inertia of the particles and gravity generallydirects the particulate down to the base of the particulate bin 364before the airstream generated by the vacuum motor 376 pulls theparticulate into the flexible hose 374.

For added protection, a mesh 394 is disposed as a barrier to the entryof particulate from the particulate bin 364 to the flexible hose 374. Inthe present example, a wire mesh with openings of approximately 1″square is being used, however, openings of ¼″ to 2″ in width have proveneffective. In this example, the mesh 394 is provided as a cylinderextending from inside the flexible hose 374 into the interior of theparticulate bin 364. However, other configurations could be used, suchas a cone, a mesh box inside the particulate bin 364 not attached to theflexible hose 0.374, etc. This effectively blocks the travel ofparticulate that has slipped through the slit 352 in the plate 326 intothe vacuum system 360 from entering the vacuum motor 376. The body 368of the particulate bin 364 is removable from the cap 366 by anystructure known in the art, such as latches. Preferably, it is a quickrelease disconnect system.

The sizing of a wooden blind having a metal head rail, a wooden bottomrail and wooden slats will now be described. The user must first scanhis or her personal ID card as has been previously described with thebar code scanner 324 to unlock the cutting center 10. The user thenscans the bar code associated with the wood blind to be sized. Thisenables the second cutting station 18 and disables the first cuttingstation 16.

While a pin locator 48 could be used to locate the wooden blind forsizing, the center clip locator 50 will be described in connection withthe sizing of the wooden blind. As illustrated in FIGS. 22 and 23, ahead rail includes an opening 86 that receives a protrusion or tabextending from clip 80. In this manner the clip is positively located onthe center of the head rail 82. The clip 80 is then positioned within aslot 78 of the center clip locator 50, which positions the clip and thehead rail relative to the second half scale 76. A pointer 74 on thecenter clip locator identifies the center position of the wooden blindto be sized relative to the cutting plane 92 of the circular saw 218.

Once the head rail and clip are located within the slot of the centerclip locator, the wooden blind bottom rail, slats and head rail are slidinto a first opening 221 in the second cutting station (See FIG. 28).The wooden blind is located by moving the center clip locator 50 toalign the pointer 74 of the center slat locator with the customer'swidth specification on the second scale 76.

Once the wooden mini-blind is at the proper location to be sized, theend locator 52 is used to square the ends of the head rail, slats andbottom rail, by using the second side extension second side 98. A clampmechanism 222 clamps the bottom rail, the wooden slats and the head railagainst a stop 224 (See FIG. 29) such that the sides of the rails andslats are parallel to the top working surface 36. This removes any spacedistance between the slats, the bottom rail and the head rail.

Once the bottom rail, slats and head rail have been located within theopening 221 and clamped against the stop 224, the first end of thewooden mini-blind is ready to be sized. Because the operator has alreadyentered his or her ID and the UPC of the blind to be sized, the secondcutting station 18 is activated. By simultaneously depressing twoactivation buttons, the following sequence is activated. The vacuummotor 376 is initiated and run for a predetermined amount of time, inthis example one second. The circular saw 218 is then activated andmoved toward the front wall 28 along the cutting plane 92. The saw 218travels along the cutting plane 92 until the bottom rail, all of theslats, and the head rail are each sized. After the sizing has beencompleted, the saw returns to its starting position.

The circular saw 218 translational speed can vary throughout threestages of the sizing operation. In the first stage, the saw ramps up toits translational cutting speed. In the second stage, the saw maintainsthe cutting speed. In this stage, the saw cuts the bottom rail, slatsand head rail until the bottom rail, all of the slats, and the head railare each sized. After the sizing has been completed, the third stage ofthe sequence begins in which the saw returns to its starting position.In the third stage, the circular saw 218 is moved at a highertranslation speed than the cutting speed such that the cycle time ismuch shorter than if the saw 218 was returned at the cutting speed. Thecircular saw 218 is moved rearward until it is in its fully withdrawnposition. In the preferred embodiment the movement of the saw isautomated and controlled by the controller 323.

The circular saw can ever have more than one translational speed throughthe cut. For example, it can translate slowly during the beginning ofthe cut, move faster, then slow down again near the end of the cut.

Large pieces of blind that have been cut fall off the plate 326 and intothe refuse bin 356. Particulate and dust are sucked by the vacuum system360 through the slit 352 and into the vacuum system 360. The particulateand dust are sucked through the sheath 362 and into the particulate bin364. Large particulate either falls into the body 368 of the bin 364 byinertia and gravity or is blocked from entering the flexible hose 374 bywire mesh 394, then falls into the body 368 of the particulate bin 364.Dust passes through the wire mesh 394 into the vacuum motor 376 and isthen pushed into and through the second flexible hose 380 and into thevacuum bag 382.

In addition to wooden slats, the circular saw 218 may also size fauxwood slats made of a cellulose plastic formulation or of slats made froma plastic material, or any other type of material that can effectivelybe sized with a circular saw. The circular saw 218 includes a circularsaw blade 220 that travels along the cutting path 92.

It is also possible to size a valance for the wooden blind at the sametime the head rail, bottom rail and slats are being sized. The valanceis simply located adjacent head rail or bottom rail and sized along withthe other components.

A vertical blind may also be sized in the second cutting station 18. Avertical blind head rail is sized in the vertical shearing mechanism 204by locating the vertical blind head rail in the vertical blind head railchannel 210. The vertical blind traverse rod is located within thetraverse rod opening 211. Since the vertical blind does not include liftcords, the vertical blind head rail may be sized by removing materialfrom a single side of the stock head rail. Accordingly, a scale 225having full scale indicia are used to determine the width of thevertical blind. Again, the width of the vertical blind is measured tocorrespond to the width of the window it will be covering. The cuttingplane of the vertical shearing mechanism 204 is not in the same plane asthe cutting plane 92 of the circular saw. The vertical shearingmechanism is set inward in the housing to permit the circular saw tofully extend along its cutting plane 92 without contacting the shearingmechanism. The scale 225 measures the actual distance to the cuttingplane of the vertical shearing mechanism 204.

The vertical shear can also include a second ferromagnetic sensor 396.The second sensor 396 works in much the same fashion as the first sensor358. Vertical head rails are large, and if a large head rail made fromsteel is inserted into the vertical blind head rail channel 210, thevertical shearing mechanism 204 could be damaged. Thus, when a steelhead rail is placed in the channel 210, the second sensor 396 sends asignal to the controller 323, which then disables the second cuttingstation 18.

The vertical shearing mechanism 204 also includes a punch 216 to placean aperture in the base of the vertical head rail a set distance fromthe cutting plane of the vertical shearing mechanism 204. The apertureis located a predetermined distance from the cut end of the head rail toreceive a portion of a snap in an end cap to be added to the verticalhead rail once it has been sized. The aperture could also be used toreceive a fastener such as a screw to secure an end cap to the headrail. Punch 216 is pivotally connected to a lever 228 that is pivotallyconnected to the vertical shearing mechanism 204. The lever 228 ispivotally connected to a head portion 230 of a rod 232 which is slidablylocated in a holder 234 attached to the movable die 212. The headportion 230 includes a base portion having a diameter larger than therod 232 and larger than the opening in the holder 234.

The operation of the vertical shearing mechanism 204 for sizing thevertical blind head rail will now be described. Since the vertical blindhead rail can be sized from removing material on one side of the headrail, no centering locating mechanism need be used. Rather, the verticalblind head rail can be measured by use of the full scale indicia onscale 224. The end of the vertical blind head rail to be cut is placedin channel 210 and the traverse rod is placed in opening 211. If a steelhead rail is placed in the channel 210, the second sensor 396 isactivated, and the second cutting station 18 is disabled. In the normalcourse, an aluminum head rail is placed in the channel 210, and thus,the cutting center 10 remains enabled, and the operator can proceed. Thefree end of the head rail that is not being sized is aligned with thefull scale indicia indicating the customer's specification for thedesired width of the vertical blind product. The vertical slats will besized to a different measurement, since the important feature of thevertical slats is their vertical length when they are placed over awindow. Once the vertical blind head rail and traverse rod are locatedin the stationary die 208 the operator activates the shearing mechanismby following the steps outlined above of scanning his or her ID code,then scanning the bar code of the vertical blind, and depressing the twoactivation buttons.

The movable die 212 will move in an upward direction until the “v”shaped shearing portion 214 contacts and shears the vertical head railand the traverse rod. Once the holder contacts the base of the headportion 230, the head portion is moved upward, thereby causing the pivotof lever 228 about its pivot point and causing the punch 216 to extenddownwards through the head rail. In this manner, an opening is formed inthe vertical head rail a predetermined distance from the sheared end ofthe vertical head rail. Once the movable die has reached its fullyextended upward position and the head rail and traverse rod have beensheared and the opening has been punched in the head rail, the movabledie is retracted downward to the starting position.

The vertical blind slats may also be sized in the second cutting station18 to a customer's specifications. The vertical slats extend in avertical position and therefore are likely to have a dimension differentthan the head rail width. The vertical slats are clamped down onto thetop working surface 36 with a vertical clamp 236 (See FIGS. 28 and 30)such that the face of the vertical slats are parallel to the top workingsurface 36. The vertical clamp 398 includes a square shaft 400 and aconvex clamping surface 402. It has been found that by cutting a blindwith the saw 220 a torque is placed on the blinds during the cut. Thiscauses the blinds to twist during the cut, and a smooth cut is difficultto produce. The shaft 400 is constructed in a shape to resist rotationduring the cut. In this example the shaft 400 has a square crosssection, although other cross-sectional shapes can be used effectively.Further, the clamping surface 402 is convex such that it has a similarshape as that of the blinds being cut. This further aids in theresistance to the blinds rotating during the cut.

If the vertical blind head rail is longer than the space between thefirst and second cutting stations 16, 18, the first cutting station 16may be lowered to a third position as discussed above to allow thevertical head rail to rest horizontally on the top working surface 36.When the first cutting station 16 is lowered to the third position, thetop of the frame 178 is substantially flush with or lower than the topworking surface. The scale extension 180 is located in housing 20 andextends the full scale 226 that measures the actual distance to thecutting plane 92.

Unlike the wooden mini-blind product in which the bottom rail, slats andbead rail are all positioned relative to the second cutting stationtogether, the vertical head rail and vertical slats are positioned andsized separately.

The cutting center 10 may further include a modem, Ethernet card, orother structure to communicate information back to a central location.In the disclosed example, the controller 323 can receive informationregarding the status and performance of the cutting center 10. Thisincludes information regarding the magnetic sensors 358 and 396, thecondition of any emergency stops, the amount of times a particularcutting apparatus has been used, etc. Further sensors can be placed todetermine the electrical current drawn to cut down a blind, the speed ofthe saw blade 220, how full the vacuum bag 382 is, etc. This informationcan be sent via modem or other structure to the central location whereengineers can review it. In this manner, the engineers can troubleshootproblems (such as a steel head rail in the saw's cutting path) andinstruct the operator via telephone how to correct the problem such thata service technician is not required to be sent on site. This can resultin substantial cost savings. Further, the engineer can monitorperformance of the cutting center 10 to determine when maintenance needsto be performed, or to diagnose a problem before a technician needs tobe dispatched.

A particularly useful blind cutting die 404 is disclosed in FIGS. 37 and38. The cutting die 404 includes a body 406 with an opening 408 sized toreceive a blind head rail and a slat opening 410. The die 404 furtherincludes a bottom rail block 412 with an opening 414 sized to receive ablind bottom rail. The bottom rail block 412 is configured to beslidable within the slat opening 410. The die body 406 includes a lowerchannel 416 and an upper channel 418. The bottom rail block 412 includesan lower profile 420 and an upper profile 422 that are configured toslide within the lower and upper channels 416 and 418, respectively. Itis useful if the upper profile 422 has a different shape than the lowerprofile 420 to prevent the bottom rail die block from being insertedbackwards. The die body is further defined by a front side 424 and arear side 426. It has also been found useful for the profiles 420 and422 to be disposed off center, such that they are closer to either thefront side 424 or the rear side 426. Again, this prevents the bottomrail block 412 from being inserted improperly. In this example, theprofiles 420 and 422 are disposed closer to the rear side 426.

The die body 406 further includes a plurality of through holes 428. Tomaintain the bottom rail die block 412 is a particular position, a pin430 is inserted into a through hole 428 and into an opening (not shown)in the bottom rail die block 412. In this manner, the bottom rail dieblock 412 can be adjusted to accommodate the amount of slats being sizedby the cutting center 10. This is helpful in that the die block 406itself can be used to hold the slats as they are being cut such thatthere is no movement of the slats during the cut.

In another embodiment, each scale is used for sizing a specific blind orshade product. Further, each scale may have a separate distinct colorthat corresponds with the color of the packaging for respective blind orshade product to be sized. As a result, an operator will be able todetermine which scale to use to size the stock blind or shade product bymatching the color of the stock blind or shade packaging with theappropriate scale. The instructions that are located on the housing mayalso be in color to further reduce the chance that the particular stockblind or shade product is sized incorrectly. Additionally, theinstructions that are located in an instruction manual may also be colorcoordinated with the scale and stock product packaging. Since the scale,packaging for the blind or shade product and instructions all share thesame color for sizing of a specific product, the chance of errordecreases, resulting in an easier process for the operator.

In a further embodiment, the locator pin may be eliminated. The blind orshade product may include a mark or feature that is located on itslongitudinal center. This mark or feature would be aligned with theappropriate marking on the appropriate scale as discussed above. Whilethe locator devices provide for a positive placement of the blind orshade product, it is possible to locate the center of the blind or shadeproduct by means of a mark such as a line placed on the product in thefactory before being shipped to the retain outlet. Of course the markcould also be placed by the operator in the retail outlet as well priorto sizing.

The stock blind or shade product would also have a feature such as anindentation, groove or protrusion on the center of the blind that couldbe used to locate the stock blind or shade product relative to thescale.

While the detailed drawings, specific examples and particularformulations given describe exemplary embodiments, they serve thepurpose of illustration only. The systems shown and described are notlimited to the precise details and conditions disclosed. Furthermore,other substitutions, modifications, changes, and omissions may be madein the design, operating conditions, and arrangement of the exemplaryembodiments without departing from the scope of the invention asexpressed in the appended claims.

1. An apparatus to cut blinds, comprising: a housing including a supportsurface and a front side, the housing including an interior; a blade,adapted to size a blind, wherein the sizing of a blind creates wastematter; a blade motor configured to power the blade and disposed in theinterior; a vacuum motor disposed in the interior; and a bag disposed inthe interior in fluid communication with the vacuum motor; wherein thevacuum motor is configured to draw the waste matter from the blade tothe bag; wherein a portion of the blade is below the support surface,the apparatus further including a sheath surrounding the portion of theblade beneath the support surface.
 2. The apparatus of claim 1, whereinthe bag is detachable.
 3. The apparatus of claim 1, wherein thedetachable bag is disposed under the support surface.
 4. The apparatusof claim 1, wherein the vacuum motor is in fluid communication with thesheath.
 5. The apparatus of claim 1, further including a bin in fluidcommunication with the sheath.
 6. The apparatus of claim 5, wherein thevacuum motor is in fluid communication with the bin.
 7. The apparatus ofclaim 6, wherein the vacuum motor is connected to the bin by a flexiblehose.
 8. The apparatus of claim 7, wherein the blade is linearlytranslatable along a cutting path and the vacuum motor is stationary,and the flexible hose is disposed in a loop to accommodate the lineartranslation of the blade relative to the vacuum motor.
 9. The apparatusof claim 1, further comprising a divider separating the interior into afirst chamber and a second chamber, the blade motor disposed in thefirst chamber and the vacuum motor disposed in the second chamber. 10.The apparatus of claim 9, further comprising a first door and a seconddoor on the housing, the first door allowing access to the firstchamber, and the second door allowing access to the second chamber. 11.An apparatus to size the length of a mini blind, comprising: a housingwith a support surface; a translatable blade adapted to size a blind,wherein the sizing of a blind creates particulate and dust, a portion ofthe blade being beneath the support surface; a particulate bin disposedin the housing configured to retain the particulate produced by theblade; a bag disposed in the housing a vacuum motor disposed in thehousing in fluid communication with the particulate bin and the bag; anda sheath around the portion of the blade below the support surface;wherein the vacuum motor is operable connected to the blade such thatupon actuation of the blade, the vacuum motor is automatically actuatedto draw the dust from the blade through the particulate bin to thevacuum motor.
 12. The apparatus of claim 11, wherein the blade is a sawblade.
 13. The apparatus of claim 12, wherein the saw blade is acircular saw blade.
 14. The apparatus of claim 11, wherein theparticulate bin is in fluid communication with the sheath.
 15. Theapparatus of claim 14, further including a flexible hose with a firstend and a second end, the first end being connected to the particulatebin, and the second end being connected to the vacuum motor.
 16. Theapparatus of claim 15, further including a breathable wire mesh disposedadjacent the first end of the flexible hose, thereby providing a barrierfrom the particulate entering the flexible hose.
 17. The apparatus ofclaim 16, whereby the mesh extends from inside the flexible hose toinside the bin.
 18. The apparatus of claim 17, whereby the mesh hasapproximately rectangular openings.
 19. The apparatus of claim 18,whereby the openings are approximately in the range of ½″ to 2″ inlength, and approximately in the range of to ½″ to 2″ in width.
 20. Theapparatus of claim 19, whereby the openings are approximately 1 inchsquare.
 21. The apparatus of claim 15, whereby the flexible hose isconnected to the bin in an upper area of the bin.
 22. The apparatus ofclaim 11, further comprising a controller to actuate the vacuum motor apredetermined amount of time prior to translation of the blade.
 23. Anapparatus to cut blinds, comprising: a housing including a supportsurface and a front side, the housing including a first chamber and asecond chamber and an entrance into the second chamber on the frontside; a saw blade adapted to size a blind, wherein the sizing of a blindcreates waste matter, a portion of the saw blade being beneath thesupport surface; a blade motor disposed in the first chamber thatactuates the blade; a vacuum motor disposed in the housing; a vacuum bagdisposed in the second chamber in fluid communication with the vacuummotor; and a sheath around the portion of the saw blade below thesupport surface; wherein the vacuum motor is configured to draw thewaste matter from the blade to the vacuum bag; and wherein the vacuumbag is disposed adjacent the entrance of the second chamber on the frontside of the housing.
 24. The apparatus of claim 23, further comprising aduct connecting the vacuum motor to the vacuum bag.
 25. The apparatus ofclaim 23, the housing further comprising a controller mechanism orientedtoward and accessible from the front side.